Display mirror assembly

ABSTRACT

A display mirror assembly for a vehicle includes a front shield having a first side and a second side. A partially reflective, partially transmissive element is mounted on the first side. A rear shield is disposed behind the front shield. A display module is mounted between the front shield and the rear shield and includes in order from the front shield: a display; an optic block; a heat sink having an edge lit PCB mounted along a top edge thereof; and a PCB. The front shield is secured to at least one component of the display module with a first retaining feature and the rear shield is secured to at least one component of the display module with a second retaining feature. A housing at least partially surrounds the partially reflective, partially transmissive element, the front shield, carrier plate, display module, and rear shield.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to and the benefit under 35 U.S.C.§119(e) of U.S. Provisional Patent Application No. 61/881,624, filed onSep. 24, 2013, entitled “DISPLAY MIRROR ASSEMBLY,” the entire disclosureof which is hereby incorporated herein by reference.

BACKGROUND OF THE DISCLOSURE

The present disclosure generally relates to a rearview device system,and more particularly, a display mirror assembly having a partiallyreflective, partially transmissive element and a display behind thereflective element.

SUMMARY OF THE DISCLOSURE

At least one aspect of the disclosure includes a display mirror assemblyfor a vehicle having a front shield including a first side and a secondside. A partially reflective, partially transmissive element is mountedon the first side. A rear shield is disposed behind the front shield. Acarrier plate is disposed between the front shield and the rear shield.A display module is mounted between the front shield and the rear shieldand includes in order from the front shield: a display; an optic block;a heat sink having an edge lit PCB mounted along a top edge thereof; anda PCB. The front shield is secured to at least one component of thedisplay module with a first retaining feature and the rear shield issecured to at least one component of the display module with a secondretaining feature. A housing at least partially surrounds the frontshield, display module, and rear shield.

At least one aspect of the disclosure includes an RF shield for adisplay mirror having a first metallic shield member with RF shieldingproperties. The first metallic shield member forms a carrier platehaving structural features configured to support a display module. Asecond metallic shield member includes RF shielding properties. Thefirst metallic shield member and the second metallic shield member eachhave retaining features to operatively engage the display moduledisposed between the first metallic shield member and the secondmetallic shield member.

At least one aspect of the disclosure includes a method of manufacturinga display mirror assembly for a vehicle. A partially reflective,partially transmissive element is affixed to a front side of a frontshield. A display module is positioned on a rear side of the frontshield and the front shield is operably secured to the display module. Arear shield is positioned on a rear side of the display module the rearshield is operably secured to the display module. The front shield, thedisplay module, and the rear shield are operably secured between a glasselement and a rear housing in a carrier plate free configuration.

At least one aspect of the disclosure includes a display mirror assemblyfor a vehicle having a housing. A mirror assembly is operably coupledwith the housing. A display module is mounted to the housing. A displayswitch is operable between an on state and an off state corresponding toactivation and deactivation, respectively, of the display module. Thedisplay module includes a printed circuit board (PCB). A bi-modal switchis rotatably coupled with the housing. The bi-modal switch is adjustableto a first position that rotates the mirror assembly to optimizevisibility of an image and which simultaneously moves the display switchto the off state. The bi-modal switch is also adjustable to a secondposition that rotates the mirror assembly to a position that is notoptimal for visibility of an image and which simultaneously moves thedisplay switch to the on state.

At least one aspect of the present disclosure includes a bi-modal switchthat is operably connected to the display module, the bi-modal switchextends outwards with respect to the housing. The bi-modal switch isconfigured to actuate to and from at least a first position and a secondposition that activate or deactivate the display module and pivot thepitch of a mirror element viewable by an occupant approximately between2 degrees and 7 degrees.

These and other features, advantages, and objects of the presentdisclosure will be further understood and appreciated by those skilledin the art by reference to the following specification, claims, andappended drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top front perspective view of a display mirror assembly fora vehicle;

FIG. 2 is a bottom front perspective view of the display mirror assemblyof FIG. 1;

FIG. 3 is a side elevation view of the display mirror assembly of FIG.1;

FIG. 4 is a partially exploded top perspective view of the displaymirror assembly of FIG. 1;

FIG. 5 is a partially exploded top perspective view of the displaymirror assembly of FIG. 1;

FIG. 6 is an exploded top perspective view of the display mirrorassembly of FIG. 1

FIG. 7A is a isometric front perspective view of a display mirrorassembly for a vehicle with a bi-modal switch;

FIG. 7B is a front perspective view of the display mirror assembly ofFIG. 7A;

FIG. 7C is a side elevation view of the display mirror assembly of FIG.7A;

FIG. 7D is a side elevation view of the display mirror assembly of FIG.7A; and

FIG. 7E is a cross-sectional side view of the display mirror of FIG. 7A;

FIG. 8A is a front elevational view of a display mirror assembly for avehicle with a bi-modal switch in a first position;

FIG. 8B is a bottom perspective view of the display mirror assembly ofFIG. 8A;

FIG. 8C is a side elevational cross-sectional view of the display mirrorassembly of FIG. 8A;

FIG. 9A is a front elevational view of a display mirror assembly for avehicle with the bi-modal switch in a second position;

FIG. 9B is a bottom perspective view of the display mirror assembly ofFIG. 9A; and

FIG. 9C is a side elevational cross-sectional view of the display mirrorassembly of FIG. 9A.

DETAILED DESCRIPTION

The present illustrated embodiments reside primarily in combinations ofmethod steps and apparatus components related to a display mirror.Accordingly, the apparatus components and method steps have beenrepresented, where appropriate, by conventional symbols in the drawings,showing only those specific details that are pertinent to understandingthe embodiments of the present disclosure so as not to obscure thedisclosure with details that will be readily apparent to those ofordinary skill in the art having the benefit of the description herein.Further, like numerals in the description and drawings represent likeelements.

For purposes of description herein, the terms “upper,” “lower,” “right,”“left,” “rear,” “front,” “vertical,” “horizontal,” and derivativesthereof shall relate to the disclosure as oriented in FIG. 1. Unlessstated otherwise, the term “front” shall refer to the surface of theelement closer to an intended viewer of the display mirror, and the term“rear” shall refer to the surface of the element further from theintended viewer of the display mirror. However, it is to be understoodthat the disclosure may assume various alternative orientations, exceptwhere expressly specified to the contrary. It is also to be understoodthat the specific devices and processes illustrated in the attacheddrawings, and described in the following specification are simplyexemplary embodiments of the inventive concepts defined in the appendedclaims. Hence, specific dimensions and other physical characteristicsrelating to the embodiments disclosed herein are not to be considered aslimiting, unless the claims expressly state otherwise.

The terms “including,” “comprises,” “comprising,” or any other variationthereof, are intended to cover a non-exclusive inclusion, such that aprocess, method, article, or apparatus that comprises a list of elementsdoes not include only those elements but may include other elements notexpressly listed or inherent to such process, method, article, orapparatus. An element proceeded by “comprises a . . . ” does not,without more constraints, preclude the existence of additional identicalelements in the process, method, article, or apparatus that comprisesthe element.

Referring now to FIGS. 1-3, reference numeral 10 generally designates adisplay mirror assembly for a vehicle. The display mirror assembly 10includes a partially reflective, partially transmissive element 12 (alsoreferred to as a “glass element” herein) and a display module 18 (FIG.6) that is viewed through the partially reflective, partiallytransmissive element 12. As shown in FIG. 4, the display mirror assembly10 further includes a front shield 14 and a rear shield 16 which shieldand support the partially reflective, partially transmissive element 12and the display module 18 (FIG. 6). As shown in FIGS. 5 and 6, thedisplay module 18 generally includes several components 20, including adisplay 22, an optic block 24, a heat sink 26, and a primary printedcircuit board (PCB) 28. A housing 30 at least partially receives thefront shield 14, the display module 18, and the rear shield 16, andincludes a mounting member 32 extending rearwardly therefrom. Themounting member 32 is adapted for mounting on a windshield of a vehicle.The housing may be configured to be part of the outer profile of thepartially reflective, partially transmissive element.

Referring generally to FIGS. 1-5, the display mirror assembly 10 has aviewing area 40 disposed on a front surface of a front substrate 42 ofthe glass element 12. The viewing area 40 may be a rectangular shape, atrapezoidal shape, or any custom contoured shape desired for aestheticreasons.

Referring to FIG. 4, the display mirror assembly 10 for a vehicle isshown, with the components partially exploded. The display mirrorassembly 10 includes the glass element 12, the front shield 14 and therear shield 16 encapsulating the display module 18, the rear housing 30,and the mounting member 32. As shown in FIGS. 4-6, the front shield 14,the rear shield 16, and components of the display module 18 includevarious retaining features to operably connect the several components ofthe display module 18 with the front shield 14, the rear shield 16 andeach other, and to provide support to the display module 18.Specifically, the front shield 14 includes retaining features tooperably connect the front shield 14 to the display module 18, and therear shield 16 has retaining features to operably connect the rearshield 16 to the display module 18. The retaining features generallyinclude snap fit connections, tab and slot connections, screwconnections, and other known retaining features. Some or all of theretaining features may also be strengthened by the addition of adhesivecompounds. Certain non-limiting illustrative examples of retainingfeatures are described in detail herein.

The display mirror assembly 10 will hereafter be described in greaterdetail, beginning with the elements closest to the intended viewer, andextending rearwardly away from the viewer.

As shown in FIG. 4, the glass element 12 is generally planar, with anouter perimeter 46 and a border around the outer perimeter 46. Theborder may incorporate a peripheral concealing layer 48 or edgetreatment, such as a chrome ring or other similar finish, to conceal aperipheral area of the front shield 14 and other elements located behindthe glass element 12 in the display mirror assembly 10, includingwithout limitation a seal on an electrochromic unit, an applique, foamadhesive, or pad printing. The border may extend from the outerperimeter 46 of the glass element 12 to an outer edge 50 of the display22. Alternatively, the border may be narrower and not reach from theouter perimeter 46 to the outer edge 50 of the display 22 along at leastsome portions of the border. The outer perimeter 46 of the glass element12 may also have a ground edge, a bezeled edge, or be frameless.

The glass element 12 may include an electro-optic element or include aprism-type construction. The prism-type construction generally includesone glass element 12 having a varying thickness from top to bottom. Withan electro-optic element, the glass element 12 includes at least twoglass substrates. For example, as illustrated in FIG. 6, the glasselement 12 includes the front substrate 42 as well as a rear substrate51. One non-limiting example of an electro-optic element is anelectrochromic medium, which includes at least one solvent, at least oneanodic material, and at least one cathodic material. Typically, both ofthe anodic and cathodic materials are electroactive and at least one ofthem is electrochromic. It will be understood that regardless of itsordinary meaning, the term “electroactive” will be defined herein as amaterial that undergoes a modification in its oxidation state uponexposure to a particular electrical potential difference. Additionally,it will be understood that the term “electrochromic” will be definedherein, regardless of its ordinary meaning, as a material that exhibitsa change in its extinction coefficient at one or more wavelengths uponexposure to a particular electrical potential difference. Electrochromiccomponents, as described herein, include materials whose color oropacity are affected by electric current, such that when an electricalcurrent is applied to the material, the color or opacity change from afirst phase to a second phase.

The electrochromic component as disclosed herein may be a single-layer,single-phase component, multi-layer component, or multi-phase component,as described in U.S. Pat. No. 5,928,572 entitled “Electrochromic LayerAnd Devices Comprising Same,” U.S. Pat. No. 5,998,617 entitled“Electrochromic Compounds,” U.S. Pat. No. 6,020,987 entitled“Electrochromic Medium Capable Of Producing A Pre-selected Color,” U.S.Pat. No. 6,037,471 entitled “Electrochromic Compounds,” U.S. Pat. No.6,141,137 entitled “Electrochromic Media For Producing A Pre-selectedColor,” U.S. Pat. No. 6,241,916 entitled “Electrochromic System,” U.S.Pat. No. 6,193,912 entitled “Near Infrared-Absorbing ElectrochromicCompounds And Devices Comprising Same,” U.S. Pat. No. 6,249,369 entitled“Coupled Electrochromic Compounds With Photostable Dication OxidationStates,” and U.S. Pat. No. 6,137,620 entitled “Electrochromic Media WithConcentration Enhanced Stability, Process For The Preparation Thereofand Use In Electrochromic Devices”; U.S. Patent Application PublicationNo. 2002/0015214 A1 entitled “Electrochromic Device”; and InternationalPatent Application Serial Nos. PCT/US98/05570 entitled “ElectrochromicPolymeric Solid Films, Manufacturing Electrochromic Devices Using SuchSolid Films, And Processes For Making Such Solid Films And Devices,”PCT/EP98/03862 entitled “Electrochromic Polymer System,” andPCT/US98/05570 entitled “Electrochromic Polymeric Solid Films,Manufacturing Electrochromic Devices Using Such Solid Films, AndProcesses For Making Such Solid Films And Devices,” which are hereinincorporated by reference in their entirety. The glass element 12 mayalso be any other element having partially reflective, partiallytransmissive properties. To provide electric current to the glasselement 12, electrical elements 52 are provided on opposing sides of theelement, to generate an electrical potential therebetween. A J-clip 54is electrically engaged with each electrical element 52, and elementwires extend from the J-clips 54 to the primary PCB 28.

Now referring to the embodiments illustrated in FIGS. 5 and 6, the frontshield 14 and the rear shield 16 function to shield the display module18 from radio frequency (RF) electromagnetic radiation and to providesupport for the glass element 12 and the display module 18. The frontshield 14 is formed from one or more materials which are suitable toblock RF radiation, including without limitation steel. As anon-limiting example, the front shield 14 can be formed from a stampedsteel material which is about 0.2 mm thick to 1.0 mm thick. In additionto preventing electromagnetic radiated emissions, the front shield 14and the rear shield 16 also protect the circuitry of the device fromelectromagnetic susceptibility (conduction).

With reference again to FIGS. 5 and 6, the front shield 14 is generallyshaped in the form of a ring 60 having an opening 62 therethrough. Thefront shield 14 has a front side 64, rear side 66, and an outer surface68 which is generally coextensive with the outer perimeter 46 of theglass element 12. The front shield 14 includes retaining features 70extending forwardly therefrom, to mechanically engage the glass element12. An adhesive, such as a foam adhesive 72, may also be used to securethe glass element 12 to the front shield 14. The front shield 14 furtherincludes rearwardly directed tabs 74 to operably engage the rear shield16 (or a component of the display module 18). The rearwardly directedtabs 74 further include holes 76 therethrough, to operably engage atleast one component of the display module 18, such as the optic block24.

As clearly illustrated in FIG. 6, the display module 18 is disposedbehind the front shield 14, with the display 22 viewable through theopening 62 in the front shield 14. The components of the display module18 are ordered, from the front shield 14 toward the rear shield 16, inthe following order: the display 22, the optic block 24, the heat sink26, and the primary PCB 28.

The display 22 is generally planar, with the outer edge 50 defining afront surface 78. The front surface 78 of the display 22 can be shapedto correspond to and fit within the shape of the viewing area 40 of thedisplay mirror assembly 10. Alternatively, the display 22 may have afront surface 78 which fits within, but is not complementary to theviewing area 40, for example, where the front surface 78 of the display22 is generally rectangular and the front substrate 42 of the glasselement 12 has a contoured outer perimeter 46. The distance between theouter edge 50 of the display 22 and the outer perimeter 46 of the glasselement 12 is about 9 mm or less along at least a portion of the outeredge 50. In one embodiment, the display 22 has a viewable front surface78 area which is about 56% to about 70% of the viewing area 40 of theglass element 12.

The display 22 may be a liquid crystal display (LCD), a light-emittingdiode (LED), an organic light-emitting diode (OLED), plasma, digitallight processing (DLP), or other display technology. The display 22further includes a flexible electrical connector 80 which is operablymechanically and electrically connected with the primary PCB 28. Theflexible electrical connector 80 has a length L that is sufficient toextend over and wrap around the display module components between thedisplay 22 and the primary PCB 28, and has a width which extendssubstantially along a top edge 82 of the display 22. Ends of theflexible electrical connector 80 may be chamfered to ease manufacturing.The flexible electrical connector 80, when operably coupled to theprimary PCB 28, aids in securing the components along a top edge of thedisplay module 18.

As shown in FIGS. 5 and 6, the optic block 24 includes a front side 90which is facing the display 22, a rear side 92 which is facing the heatsink 26, and an outer perimeter 94. The optic block 24 further includestabs 96 extending generally outwardly therefrom around at least aportion of the outer perimeter 94. In the illustrated embodiment, thetabs 86 extend from sides of the optic block 24. However, it iscontemplated that the tabs 96 could be located anywhere along theperiphery of the optic block 24. The tabs 96 are received through theholes 76 in the rearwardly directed tabs 74 of the front shield 14, tooperably couple the optic block 24 with the front shield 14. The opticblock 24 further includes at least one receiving element 98 forreceiving a mechanical fastener on the rear side 92 thereof. Thereceiving elements 98 are adapted to engage mechanical fasteners 100threaded through the rear shield 16 and the display module 18 componentsbetween the optic block 24 and the rear shield 16. In alternateembodiments, the tabs 96 for engaging the front shield 14, thescrew-receiving elements 98, or both, could be provided on differentcomponents of the display module 18.

As shown in FIGS. 4 and 6, a glare sensor optic 102 is provided on thefront side 90 of the optic block 24, in a location which receives lightthrough the glass element 12, and which is not behind the display 22.The glare sensor optic 102 is snap-fit into a receiving aperture 104 inthe optic block 24. The glare sensor optic 102 receives light fromheadlamps of a trailing vehicle, and measures information regarding thelikely glare visible on the glass element 12 and communicates thisinformation to the display mirror assembly 10 so that the display mirrorassembly 10 can be optimized to allow viewing of the display 22 throughthe glass element 12. The glare sensor optic's 102 opticalvertical/horizontal pattern is symmetrical, so that orientation of theglare sensor optic 102 is not significant as shown in its circulargeometry. The glare sensor optic 102 could also have an asymmetricalvertical/horizontal light gathering pattern, in which case a keyedfeature would be put into the lens to verify correct orientation in thedisplay mirror assembly 10. The glare sensor optic 102 could also bepackaged at least partially within the housing 30 of the display mirrorassembly 10 and have a light guide which is configured to propagatelight to the glare sensor optic 102. The glare sensor optic 102 couldalso be an imager on a rear portion of the vehicle, wherein a signalrepresentative of the received light is communicated from the glaresensor optic 102 to the display mirror assembly 10.

With reference again to FIGS. 5 and 6, the heat sink 26 is disposedrearwardly from the optic block 24, and dissipates heat generated by theprimary PCB 28 and other components of the display module 18. The heatsink 26 has a generally planar body 110 with a front side 112 and a topedge 114. A channel 116 extends along the top edge 114 of the heat sink26, and defines a forward-facing opening 118. An edge lit PCB 120 and agap filler or thermal interface material 122 are disposed partiallywithin the channel 116, with the edge lit PCB 120 extending generallyperpendicularly from the heat sink 26 in a forward direction, and havingan operable side which is facing downward, away from the top edge 114.The edge lit PCB 120 includes a wiring adapted for electrical connectionwith the primary PCB 28, to permit electrical power and signals to besupplied to the edge lit PCB 120. The gap filler 122 could be a gapfiller pad, a thermally conductive epoxy, or other material used toincrease the heat transfer from the edge lit PCT 120 to the heat sink26. A plurality of tabs 128 extend upwardly from the top edge 114 of theheat sink 26, for mechanical engagement with the rear shield 16.

The heat sink 26 also includes at least one hole 130 therethrough toreceive a mechanical fastener 100 threaded from the rear shield 16 tothe optic block 24. The receiving element 98 of the optic block 24 isoptionally raised, to extend through the at least one hole 130 in theheat sink 26 and receive the mechanical fastener 100. The receivingelement 98 of the optic block 24 may also aid in alignment of thecomponents of the display module 18 during manufacturing and willprovide additional reinforcement to the display module 18 in theinteraction between components if it is raised. Moreover, the receivingelement 98 both secures the components of the display module 18 togetherand aids in maintaining proper spacing of the components.

The primary PCB 28 operates to provide electrical power and control forthe components of the display module 18 and for the glass element 12. Asshown in FIGS. 5 and 6, the primary PCB 28 is generally planar, with afront side 140, a rear side 142, and side edges 144. The front side 140faces the heat sink 26 and the rear side 142 faces the rear shield 16.Electrical components are generally oriented on both sides of theprimary PCB 28. The primary PCB 28 includes an electrical connector foroperable electrical engagement with the electrical element wires of theglass element 12, an electrical connector for operable electricalengagement with the flexible electrical connector 80, and an electricalconnector for operable electrical engagement with the wiring harness.Additional functional elements that may be provided on the displaymirror assembly 10 may also be electrically connected to the primary PCB28, such as the glare sensor optic 102 and any other functional buttonsor features of the display mirror assembly 10. The primary PCB 28further includes side cutouts 150 along the side edges 144, to permitpassage of the mechanical fasteners 100 used to secure the rear shield16 to the components of the display module 18.

With reference again to FIGS. 4 and 5, the rear shield 16 also serves toencapsulate the display module 18, and further interlock the componentsof the display mirror assembly 10. The rear shield 16 functions toshield the display module 18 from RF radiated and conducted emissions.The rear shield 16 is formed from a material which is suitable to blocksuch radiation and provide the desired support for the display mirrorassembly 10, such as steel. As a non-limiting example, the rear shield16 can be formed from stamped steel with a thickness of about 0.2 to 1mm. It is also contemplated that a welded or die-formed rear shield 16could be provided.

As shown in FIG. 6, the rear shield 16 includes a rear wall 160 havingan outer perimeter 162, and a peripheral wall 164 extending forward fromthe rear wall 160 about at least a portion of the outer perimeter 162.The peripheral wall 164 has slots 166 therein, which correspond to theupstanding tabs 128 along the top edge 114 of the heat sink 26 and areoperably mechanically engageable therewith. The rear shield 16 furtherincludes at least one hole 168 there through to accommodate themechanical fastener 100, where the mechanical fastener 100 extendsthrough the rear shield 16 and into the components of the display module18 to secure the rear shield 16 to the display module 18. The mechanicalfastener 100 extends through the rear wall 160 of the rear shield 16,through the side cutouts 150 of the primary PCB 28, through the heatsink 26, and is secured to the screw-receiving element 98 on the rearside 92 of the optic block 24.

As shown in FIG. 6, the rear housing 30 includes a forwardly directedcavity 170, into which all or a portion of the front shield 14, rearshield 16, and the display module 18 supported therebetween areinserted. The rear housing 30 includes mechanically engaging features172 which snap fit with corresponding engagement features 174 located onthe peripheral wall 164 of the rear housing 30 or on a display module 18component such as the heat sink 26. The mounting member 32 is operablyengaged with the rear housing 30 in any known manner.

With respect to the following description, the display mirror assembly10 is considered “on axis” when a line perpendicular to the plane of theglass element 12 extends toward the eyes of a viewer. Due to the display22 being viewed through the glass element 12, any glare on the glasselement 12 may interfere with the visibility of the display 22. When thedisplay mirror assembly 10 is on axis and is being used during nighttime driving conditions, headlights from a trailing vehicle (i.e., avehicle driving behind the vehicle with the display mirror assembly 10)can cause a glare which is visible to the driver. According to oneembodiment of the present disclosure, an actuator device 176, as shownin FIGS. 2 and 6, is operably coupled to the display mirror assembly 10.When actuated, the actuator device 176 moves at least the glass element12 off axis (i.e., away from a direct line toward the driver's eyes).Typically, actuation of the actuator device 176 tilts the glass element12 upwards, to move the mirror to an off-axis position. However, itshould be appreciated that the actuator device 176 can be configured tomove the mirror in any direction with respect to the axis. The actuatordevice 176 can also be configured to move the display 22 uponactivation. The actuator device 176 can also be configured to turn thedisplay 22 on or off. Thus, when the actuator device 176 is actuated tomove the mirror off axis, the display 22 can be turned off. Typically,when the actuator device 176 is actuated, the display mirror assembly 10rotates with the glass element 12 and the display 22, keeping a constantdistance relationship to each other. When the actuator device 176 isactivated, the mounting member 32 and flipper plate do not move withrespect to the rest of the vehicle. In the illustrated embodiment, theglass element 12 and the display 22 are rigidly affixed to each otherand do not move independently of one another. Alternatively, the glasselement 12 could be configured to move independently of the display 22.Additionally, to provide information to the viewer of the display mirrorassembly 10, the display mirror assembly 10 may include informationregarding the field of view 178, such as a partially transmissivegraphic overlay or an image on the display 22 visible on the viewingarea 40 when the display mirror assembly 10 is in use.

In order to construct the display mirror assembly 10 described herein,the J-clips 54 are installed on the glass element 12, and then elementwires are soldered to the top portion of the J-clips 54. The glasselement 12 is then secured to the front side 64 of the front shield 14,using the foam adhesive 72 and the forward retaining features 70 of thefront shield 14. The front shield 14 is then inverted, with the glasselement 12 facing downwardly on a protective surface.

A first subassembly 180 (FIG. 5), including the display 22 and opticblock 24, is assembled by snap-fitting the glare sensor optic 102 intothe receiving aperture 104 in the optic block 24, and adhering thedisplay 22 to the optic block 24. The adhesion of the display 22 andoptic block 24 may include coating the front side 90 of the optic block24 with an adhesive and applying a release liner over the adhesive,wherein the release liner is easily removable from the adhesive. When itis time to assemble the display 22 and optic block 24, the release lineris removed, and the display 22 is positioned on the front side 112 ofthe optic block 24. To position the display 22, one edge of the display22 is aligned in the appropriate location on the optic block 24, andthen the display 22 is rotated into contact with the front side 90 ofthe optic block 24. The first subassembly 180 is placed in position onthe rear side 66 of the front shield 14. The tabs 96 extending outwardlyfrom the optic block 24 are inserted through the holes 76 in therearwardly directed tabs 74 of the front shield 14.

A second subassembly 182 (FIG. 5), including the heat sink 26 and edgelit PCB 120, is assembled. To assemble the second subassembly 182, thegap filler 122 is adhered to the edge lit PCB 120. The adhesion mayinclude coating one side of the gap filler 122 with adhesive and thenapplying the gap filler 122 to the edge lit PCB 120 so that it does notinterfere with the operable side of the edge lit PCB 120. The gap filler122 and edge lit PCB 120 are then inserted into the opening in thechannel 116 on the front side 112 of the heat sink 26. Locating featuresare optionally provided on the heat sink 26, the edge lit PCB 120 orboth, to aid in inserting the side lit PCB and gap filler 122 into thechannel 116. The second subassembly 182 is placed in position on therear side 92 of the optic block 24. The screw-receiving elements 98extending rearwardly from the optic block 24 extend through the holes130 in the heat sink 26.

The primary PCB 28 is placed above the top edge of the secondsubassembly 182, with the front side 140 facing upwards. The flexibleelectrical connector 80 from the display 22 is mated with the electricalconnector therefor. The primary PCB 28 is then rotated 180 degrees aboutthe top edge of the second subassembly 182, so that the front side 140is in contact with the heat sink 26. When rotating the primary PCB 28,the flexible electric connector is wrapped over the top edge of at leasta portion of the display module 18. The element wires are electricallyconnected with the electrical connectors therefor, and the wiringharness for the edge lit PCB 120 is connected with the electricalconnector therefor.

As shown in FIGS. 4 and 5, the rear shield 16 is placed over the primaryPCB 28, and the tabs 128 extending upwardly from the heat sink 26 areengaged with the slots 166 on the peripheral wall 164 of the rear shield16. At least one screw 100 is inserted through the screw holes 168 inthe rear shield 16, through the side cutouts 150 in the PCB, through theheat sink 26, and into the screw-receiving elements 98 on the opticblock 24. It is desirable that two to three screws 100 are affixed inthis manner. Heat stakes or other mechanical fastening devices could beused to subassembly together.

The forwardly directed cavity 170 of the rear housing 30 is placed overthe rear shield 16, and the mechanically engaging features 172 of therear housing 30 are snap fit to engage with the corresponding engagementfeature 174 of the heat sink 26. The mounting member 32 may be installedin the rear housing 30 prior to assembly.

The present disclosure may be used with a mounting system such as thatdescribed in U.S. Pat. Nos. 8,814,373; 8,201,800; and 8,210,695; U.S.Patent Application Publication Nos. 2014/0063630; 2013/0062497; and2012/0327234; and U.S. Provisional Patent Application Nos. 61/709,716;61/707,676; and 61/704,869, which are hereby incorporated herein byreference in their entirety. Further, the present disclosure may be usedwith a rearview packaging assembly such as that described in U.S. Pat.Nos. 8,814,373; 8,646,924; 8,643,931; and 8,264,761; U.S. PatentApplication No. 2013/0194650; and U.S. Provisional Patent ApplicationNos. 61/707,625; and 61/590,259, which are hereby incorporated herein byreference in their entirety. Additionally, it is contemplated that thepresent disclosure can include a bezel such as that described in U.S.Pat. Nos. 8,827,517; 8,210,695; and 8,201,800, which are herebyincorporated herein by reference in their entirety.

The display mirror assembly according to the present disclosure hasseveral advantages. The display module is supported by the front shieldand rear shield, and does not require a separate support or carrierplate. Omission of a carrier plate, and inclusion of retaining featuresin the front shield and rear shield, permits the display mirror assemblyto be lighter, involve less parts for manufacturing, and to have adisplay which is viewable over a larger percentage of the total viewingarea of the display mirror assembly.

As shown in FIGS. 7A-7E, the display mirror assembly 10 can include oneor more of the elements of FIGS. 1-6, and the housing 30 can be modifiedto be proud of the partially reflective, partially transmissive element12. Additionally or alternatively, the display mirror assembly caninclude an external bi-modal switch 200 configured to at least one ofactivate and deactivate the display module 18 and alter a position ofthe partially reflective, partially transmissive element 12 to alternatebetween a first position and a second position.

As shown in FIGS. 7C and 7D, the bi-modal switch 200 can be located atthe bottom of the housing 30. When the operator actuates the bi-modalswitch 200, the display 22 is either activated or deactivated and/or thedisplay mirror assembly 10 pivots between approximately 2 degrees and 7degrees in the direction of the dotted lines, allowing for the displaymirror assembly 10 to alternate between a first position and a secondposition. In one embodiment, it is contemplated that the operator couldput the display mirror assembly 10 in the deactivated mode and adjustthe position of the display mirror assembly 10 until the image in thepartially reflective, partially transmissive element 12 is what could beexpected to be seen when using a traditional mirror system. This willallow for the operator to immediately return to their desired reflectiveimage when turning the display back to the off position. For purpose ofexplanation and not limitation, FIG. 7C generally illustrates a displaymirror assembly 10 with the bi-modal switch 200 in the on position,which activates the display 22 and changes the angle of the partiallyreflective, partially transmissive element 12 with respect to anoccupant. When the display 22 is on, the display mirror assembly 10 canbe pivoted between approximately 2 degrees and 7 degrees anapproximately vertical direction relative to the position the displaymirror assembly 10 was in when off. FIG. 7D generally shows a displaymirror assembly 10 with a bi-modal switch 200 in the off position, thepartially reflective, partially transmissive element 12 is in thereflectance state so the user is viewing an image to the rear of thevehicle. Pivoting the display mirror assembly 10 when the display 22 isactivated can reduce unwanted reflections that detract the displayedimage. In both day and night time driving conditions, unwantedreflections can occur (e.g., backgrounds with high levels of ambientlight, headlamps—the reflection may not line up with the headlamps shownin the display 22). Notably, if the display mirror assembly 10 was usedwithout the bi-modal switch 200, the display mirror assembly 10 wouldlikely be operated with the EC function as well. However, this causescolor shift over the display 22 and causes other problems with trying tokeep the display 22 intensity constant while the EC element istransitioning between dark and clear states.

Referring now to FIG. 7E, a cross-sectional view of a display mirrorassembly includes a partially reflective, partially transmissive element12, a display 22, an optic block 24, a heat sink 26, and a primary PCB28. A housing 30 can at least partially receive the front shield 14, thedisplay module 18, and the rear shield 16. An adhesive, such as but notlimited to, a foam adhesive 72, may also be used to secure the glasselement 12 to the front shield 14. The display module 18 and optic block24 can be supported by a carrier or support plate 202 rather than onlythe front shield 14 and rear shield 16. The wall stock thickness of thecarrier or support plate 202 can be approximately 1.5 mm, oralternatively, have a thickness anywhere from 1.0 mm to 2.0 mm, whichcan enhance the amount of viewable area of the display module 18 whilemaintaining adequate support for the display mirror assembly 10.

With reference to FIGS. 8A-9C, the bi-modal switch functionalityconsists of the interaction between the mounting member 32, a mountingmember plate 34, a first pivot axis 300, a second pivot axis 302, abi-modal switch spring 304, the bi-modal switch 200, the primary PCB 28,a display switch 306, the rear housing 30, the display 22, and thepartially reflective, partially transmissive element 12, which are bothrigidly attached to the rear housing 30. The first pivot axis 300 isdefined by a cylindrical rotation member disposed between the rearhousing 30 and the mounting member plate 34. The second pivot axis 302is defined by a cylindrical rotation member disposed between the rearhousing 30 and the bi-modal switch 200. The bi-modal switch 200 rotatesabout the second pivot axis 302 when the bi-modal switch 200 is movedfrom the on position to the off position. During the rotation of thebi-modal switch 200, the mounting member 32 and the mounting memberplate 34 do not move relative to the observer of the display mirrorassembly 10. However, the rear housing 30, the display 22, the primaryPCB 28, and the partially reflective, partially transmissive element 12rotate around the first pivot axis 300. The bi-modal switch 200 rotatesapproximately 75 to 105 degrees around the second pivot axis 302. Thedistance from the center of the second pivot axis 302 to a springreceiving area 308 of the bi-modal switch 200 and the bi-modal switchspring 304 is fairly small when compared to the distance between thefirst pivot axis 300 and the spring receiving area 308 between thebi-modal switch 200 and the bi-modal switch spring 304. The differencein distances between the first pivot axis 300 and the second pivot axis302 causes a rotation of the rear housing 30 of approximately 2 to 7degrees when the bi-modal switch 200 is rotated 75 to 110 degrees. Thedisplay switch 306 is rigidly mounted to the primary PCB 28 with apredetermined distance between the mounting member plate 34 and thedisplay switch 306, such that when the bi-modal switch 200 is in the onposition (FIGS. 7C and 8A-8C), the display switch 306 is not depressed,and when the bi-modal switch 200 is in the off position, the displayswitch 306 is depressed (FIGS. 7D and 9A-9C).

With reference again to FIGS. 8A-9C, the rotation of the bi-modal switch200 generally performs two functions, the first of which is rotating thepartially reflective, partially transmissive element 12 between 2 and 7degrees, the second of which is to move the display switch 306 betweendepressed (activated) and not depressed (deactivated) positions, whichswitches the display 22 on and off, depending on the mode. Notably, theon/off depressed/not depressed state can be in either orientation and isnot critical for the function of the display mirror assembly 10. Stateddifferently, the display switch 306 can be configured to activate thedisplay 22 when depressed and deactivate the display 22 when notdepressed. Alternatively, the display switch 306 can be configured todeactivate the display 22 when depressed and activate the display 22when not depressed. In one embodiment, it is contemplated that when thedisplay 22 is off and the mirror is rotated to optimize visibility of animage, the display switch 306 is in the off state and the display 22 isdeactivated. When the bi-modal switch 200 is moved so that the reflectedimage is not optimized for visibility, the display switch 306 is in theon state and the display 22 is activated.

It will be appreciated that embodiments of the disclosure describedherein may be comprised of one or more conventional processors andunique stored program instructions that control one or more processorsto implement, in conjunction with certain non-processor circuits, some,most, or all of the functions of a display mirror assembly 10, asdescribed herein. The non-processor circuits may include, but are notlimited to signal drivers, clock circuits, power source circuits, and/oruser input devices. As such, these functions may be interpreted as stepsof a method used in using or constructing a classification system.Alternatively, some or all functions could be implemented by a statemachine that has no stored program instructions, or in one or moreapplication specific integrated circuits (ASICs), in which each functionor some combinations of certain of the functions are implemented ascustom logic. Of course, a combination of the two approaches could beused. Thus, the methods and means for these functions have beendescribed herein. Further, it is expected that one of ordinary skill,notwithstanding possibly significant effort and many design choicesmotivated by, for example, available time, current technology, andeconomic considerations, when guided by the concepts and principlesdisclosed herein will be readily capable of generating such softwareinstructions and programs and ICs with minimal experimentation.

It will be understood by one having ordinary skill in the art thatconstruction of the described disclosure and other components is notlimited to any specific material. Other exemplary embodiments of thedisclosure disclosed herein may be formed from a wide variety ofmaterials, unless described otherwise herein.

For purposes of this disclosure, the term “coupled” (in all of itsforms, couple, coupling, coupled, etc.) generally means the joining oftwo components (electrical or mechanical) directly or indirectly to oneanother. Such joining may be stationary in nature or movable in nature.Such joining may be achieved with the two components (electrical ormechanical) and any additional intermediate members being integrallyformed as a single unitary body with one another or with the twocomponents. Such joining may be permanent in nature or may be removableor releasable in nature unless otherwise stated.

It is also important to note that the construction and arrangement ofthe elements of the disclosure as shown in the exemplary embodiments isillustrative only. Although only a few embodiments of the presentinnovations have been described in detail in this disclosure, thoseskilled in the art who review this disclosure will readily appreciatethat many modifications are possible (e.g., variations in sizes,dimensions, structures, shapes and proportions of the various elements,values of parameters, mounting arrangements, use of materials, colors,orientations, etc.) without materially departing from the novelteachings and advantages of the subject matter recited. For example,elements shown as integrally formed may be constructed of multiple partsor elements shown as multiple parts may be integrally formed, theoperation of the interfaces may be reversed or otherwise varied, thelength or width of the structures and/or members or connector or otherelements of the system may be varied, the nature or number of adjustmentpositions provided between the elements may be varied. It should benoted that the elements and/or assemblies of the system may beconstructed from any of a wide variety of materials that providesufficient strength or durability, in any of a wide variety of colors,textures, and combinations. Accordingly, all such modifications areintended to be included within the scope of the present innovations.Other substitutions, modifications, changes, and omissions may be madein the design, operating conditions, and arrangement of the desired andother exemplary embodiments without departing from the spirit of thepresent innovations.

It will be understood that any described processes or steps withindescribed processes may be combined with other disclosed processes orsteps to form structures within the scope of the present disclosure. Theexemplary structures and processes disclosed herein are for illustrativepurposes and are not to be construed as limiting.

It is also to be understood that variations and modifications can bemade on the aforementioned structures and methods without departing fromthe concepts of the present disclosure, and further it is to beunderstood that such concepts are intended to be covered by thefollowing claims unless these claims by their language expressly stateotherwise.

What is claimed is:
 1. A display mirror assembly for a vehicle,comprising: a front shield configured to block RF radiation and having aforward side and a rearward side, wherein a partially reflective,partially transmissive element is mounted on the forward side; a rearshield disposed behind the front shield; a carrier plate disposedbetween the front shield and the rear shield; a display module mountedbetween the front shield and the rear shield and including: a display;an optic block disposed behind the display; a heat sink proximate to theoptic block and having an edge lit PCB mounted along a top edge thereof;and a primary PCB, wherein the front shield is secured to at least onecomponent of the display module with a first retaining feature and therear shield is secured to at least one component of the display modulewith a second retaining feature; and a housing which at least partiallysurrounds the partially reflective, partially transmissive element, thefront shield, carrier plate, display module, and rear shield.
 2. Thedisplay mirror assembly of claim 1, wherein the first retaining featureoperatively engages the front shield with the optic block, and whereinthe second retaining feature operatively engages the rear shield withthe heat sink and the optic block.
 3. The display mirror assembly ofclaim 1, wherein the partially reflective, partially transmissiveelement is an electrochromic member.
 4. The display mirror assembly ofclaim 3, wherein the edge of the partially reflective, partiallytransmissive element has a chrome ring edge treatment.
 5. The displaymirror assembly of claim 4, wherein the distance from an outer edge of afront face of the partially reflective, partially transmissive elementto an outer edge of a front face of the display module is less thanabout 9 mm.
 6. The display mirror assembly of claim 1, wherein thedisplay has a shape which corresponds to the shape of the partiallyreflective, partially transmissive element, and wherein the display isan LCD, LED, OLED, plasma, or DLP display element.
 7. The display mirrorassembly of claim 1, further comprising: a glare sensor optic engagedwith the optic block.
 8. The display mirror assembly of claim 1, furthercomprising: a partially transmissive graphic overlay which providesinformation to a viewer regarding the field of view shown in the displaymirror assembly.
 9. The display mirror assembly of claim 1, wherein thedisplay module is capable of displaying an image which providesinformation to a viewer regarding the field of view shown in the displaymirror assembly.
 10. The display mirror assembly of claim 1, wherein theprimary PCB is electrically coupled with an external bimodal-switchdisposed on the housing.
 11. A display mirror assembly for a vehicle,comprising: a front shield configured to block RF radiation and having afirst side and a second side, wherein a partially reflective, partiallytransmissive element is mounted on the first side; a rear shielddisposed behind the front shield; a display module mounted between thefront shield and the rear shield and including in order from the frontshield: a display; an optic block; a heat sink having an edge lit PCBmounted along a top edge thereof; and a primary PCB, wherein the frontshield is secured to at least one component of the display module with afirst retaining feature and the rear shield is secured to at least onecomponent of the display module with a second retaining feature; ahousing which at least partially surrounds the partially reflective,partially transmissive element, the front shield, display module, andrear shield; and a bimodal switch operably connected to the partiallyreflective, partially transmissive element, the bimodal switch operablebetween a first position and a second position.
 12. The display mirrorassembly of claim 11, further comprising: a glare sensor optic engagedwith the optic block.
 13. The display mirror assembly of claim 11,further comprising: a partially transmissive graphic overlay whichprovides information to a viewer regarding the field of view shown inthe display mirror assembly.
 14. The display mirror assembly of claim11, wherein the display module is capable of displaying an image whichprovides information to a viewer regarding the field of view shown inthe display mirror assembly.
 15. The display mirror assembly of claim11, wherein the primary PCB is electrically coupled with the bi-modalswitch which extends externally from the housing.
 16. A display mirrorassembly for a vehicle, comprising: a front shield having a forward sideand a rearward side, wherein a partially reflective, partiallytransmissive element is mounted on the forward side; a rear shielddisposed behind the front shield; a carrier plate disposed between thefront shield and the rear shield; a display module mounted between thefront shield and the rear shield and including: a display; an opticblock disposed behind the display; a heat sink proximate to the opticblock and having an edge lit PCB mounted along a top edge thereof; and aprimary PCB, wherein the front shield is secured to at least onecomponent of the display module with a first retaining feature and therear shield is secured to at least one component of the display modulewith a second retaining feature; and a housing which at least partiallysurrounds the partially reflective, partially transmissive element, thefront shield, carrier plate, display module, and rear shield; and anexternal bimodal switch disposed on the housing and electrically coupledwith the primary PCB.
 17. The display mirror assembly of claim 16,wherein the bimodal-modal switch is configured to at least one ofactivate or deactivate the display.
 18. The display mirror assembly ofclaim 16, wherein the bimodal-switch pivots the mirror assemblyapproximately between 2 degrees and 7 degrees with respect to anoccupant.